The wires needed for the harness are first cut to the desired length and labeled appropriately. This will include detailed assembly steps, images and illustrations, and test procedures. Every wire harness is different, however, the basics of wire harness construction is pretty much the same. You should also provide generic specifications for wires, such as 300V or 600V, instead of a specific UL code. If not, they will search for available replacements. The next step usually involves wire cutting, stripping, and terminating. These benef… and precise specifications you can provide, the fewer problems there will be on the assembly floor. Below you will find our image gallery from the cable assemblies manufacturing process. However, we’ll show how this seemingly simple process can absolutely make or break your project and the best methods used by the best manufacturers in the business to ensure a perfect crimp, every time. Manual production remains the most cost-effective method of assembling wire harnesses because the process of that assembly is too difficult to automate. , and performance. We will consult with you about your proposed design, as well as the problem that your design is intended to solve. Cut to your company’s specifications. Assembling a wire harness is a complex process. It starts with the design process and making sure that the harness incorporates any necessary custom features for its intended application. Quality standards are very high, particularly in the heavy transportation and off road vehicle and equipment sectors, with minimal error rates allowable. A wire harness, on the other hand, will provide the connectivity between systems in an electromechanical assembly, such as connecting a power supply to a motherboard. Here is a sampling of the data that will best help your contract manufacturer when building your wire harness: With the documentation in hand, you should expect your contract manufacturer to follow a general process in building your wire harness: The building of your wire harness is a pretty straightforward operation, but there are some details you should be aware of to help to speed the assembly through manufacturing. Today, as I work with wire harnesses that are built for electronic devices, I am reminded of those days coaching the kids on how to put the play together. We strive to provide the highest quality wire harness and cable assemblies in the industry. Fully automatic block loading and wire harness manufacturing will become increasingly important in the future. We always encourage our customers to work with us early in the development of a wire harness so we can help you to select the best performing parts. This includes all possible variants of the wire harness, based on all possible options for a … This way, the harness is laid out to the exact dimensions that are required. Assembling wire harnesses is a step by step procedure. After this, the ends of the wires are then stripped to expose the core of the wires. There is one thing that stands out in my mind, however, and that was when a play worked the way we designed it. The design includes all possible variants of the wire harness, based on all possible options for a particular vehicle model. A wire harness is an assembly of wires, cables and connectors that transmit electric power or signals. The manufacturing process for wire harnesses can go from basic to very complex. These harnesses are important because they organize wires for easy implementation into equipment and systems. As a matter of fact, the common theme in most customer requirements is to reduce … Wire lists that specify wire colors, nets, and connector pin-outs. The very first step in assembling a wire harness is to cut the wires to the desired length, usually done by a special wire-cutting machine. The harness will also be checked for construction and labeling, and tested for fit if the system that it is intended for is on-site. They will also evaluate your specified parts to see if those are the best choices due to cost. The engineers at the wire harness manufacturer use this drawing to create a production drawing, a work plan and corresponding parts lists. Today, approximately 85% of all wire harness manufacturing operations are carried out manually. To distinguish between the two, a cable assembly is an external connection to devices and will have different environmental considerations, such as their thickness, insulation type, and flexibility. Your email address will not be published. Manual assembly is still the most common method for wire harness manufacturing because routing cables or wires through sleeves is an extremely delicate process. We first diagramed the play out for the kids, and then we practiced it until they understood the moves. Contract manufacturers often build both cable assemblies and wire harnesses. Variosystems wire harness production video Sri Lanka. Then, the harness is meticulously laid out, just as we demonstrated to the kids how to execute the play. Our wire harness manufacturing process utilizes standard processes that provide consistency, quality and ensure your product is built efficiently. To distinguish between the two, a cable assembly is an external connection to devices and will have different environmental considerations, such as their thickness, insulation type, and flexibility. Wire harnesses oftentimes get confused for cable assemblies. The vehicle manufacturer provides a 150-percent-drawing of the design of his on-board wiring system to the wire harness manufacturer. Tubing, Loom, Heat Shrink, Wire and more. Wire harness manufacturing continues to be an extremely labor-intensive process (Figure 2). Manufacturing wire harness and cable assemblies can be a complex process, but Omega Leads has the experience and knowledge to do it right every time. Manual operations for wire harness assembly include: At Precision Manufacturing Company, Inc. (PMCI), we work with clients from wire harness design and schematic development into prototyping and production. Zuken, in concert with our customers and partners, is tirelessly working to simplify the harness manufacturing process. Wire Harness Manufacturing Is a well-established company providing contract assembly of cable assemblies/wire harnesses, and electromechanical assemblies.Our customers rely on us for small to large production volumes, with both short run and weekly production capabilities. Our wire harnesses are offered as a turnkey solution, which includes every process from conception through installation. We submit every wire harness to electrical safety testing to ensure it is safe for use. Even more troublesome is the fragmentation between the harness design and manufacturing … Arcadia Harness Manufacturing enables Harness Manufacturers to save significant time, avoid duplication of data and minimise errors in their workflow with automatic tools to produce full-scale formboards and generate documentation to give to manufacturing. Find out what a difference VSE’s experts can make. Wire Harnesses No wire harness project is too difficult for Wise Harness Solutions. Standardization is the core component of lean manufacturing. in the wire harness manufacturing process. Full assembly drawing with label locations, assembly instructions and tolerances. Standardizing the manufacturing process was an immediate requirement. At the same time as procurement, the CM will be creating assembly documentation for the manufacturing floor based on your input. Usually, you specify these dimensions, and contract manufacturers are used to getting a wide range of information to work with. What Are the IPC Component Spacing Guidelines. The wire harness manufacturing process can be challenging given the manual assembly tasks it involves, and the specifications that must be met. The same goes for torque values on fasteners, in which you should also use the manufacturer’s recommended values. We can process many different materials cut to length. . This process ensures that the harness was constructed properly. WHMA is the ONLY trade association exclusively representing the cable & wiring harness manufacturing industry including manufacturers, suppliers and customers. At VSE, we have been building wire harnesses for our customers for a long time. During this phase, each harness has its electrical connections tested using sophisticated computer software. We understand that standards are extremely important to wire harness manufacturing and OEM’s. It starts with the design process and making sure that the harness incorporates any necessary custom features for its intended application. Required fields are marked *. Wire harnesses are laid out and built on a panel that has pegs positioned strategically where the wires will branch out into different directions, or connectors need to be added. The information can be something as simple as a hand-drawn note, or a series of complex 3D CAD models, as well as everything in between. Finally, the cables or wires are bound with an outer covering using an assembly board, which guides proper breakouts and allows for final electrical testing. Engineering and manufacturing methods common across the industry have been in use for decades, and are showing their limitations in a new era. Our mission at Wise Harness Solutions is to continually strive to improve our products and service to meet and exceed our customers’ expectations and requirements. This article presents the ultimate guide to wire harness manufacturing. San Jose, CA 95119, If you are looking for a CM that has the industry experience to build your wire harnesses to the, Input: What Your CM Needs for the Wire Harness Manufacturing Process. Following the schematic design to assemble wire harnesses is a manufacturing process still done mostly by hand. However, as with anything that is manufactured, the more detailed documentation and precise specifications you can provide, the fewer problems there will be on the assembly floor. The wires are stripped and cut at the right length and metal terminals are attached to the ends of the wires all using a specialized machine commonly known as a crimp center. We also have a. who can answer your questions on wire harnesses and offer recommendations on how best to design them. We always encourage our customers to work with us early in the development of a wire harness so we can help you to select the best performing parts. Wire Harness Manufacturing/Assembly Process. Connectors will be added, bundles of wires will be tied together, and labels will be attached. Once the bill of materials is finalized, the CM will next purchase the components and materials needed for production and test of the harness. Steps to Build a Wire Harness : The following points showcase the basic requirements and steps to build a wire harness. First, the wire harness specifications are drawn up in the same way we would diagram the play. In this blog, we will discuss everything you need to know about wire harnesses, including what they are, how they are used, and how they are manufactured. The assembly technicians will cut the wire to length, and lay it out on the assembly panel according to the build instructions. Every harness is validated 100% for electrical continuity. Valley Services Electronics Custom Wire Harnesses Custom wire harnesses fall well within our expertise. It keeps the components organized and provides a layer of protection in case of harsh conditions, abrasions or friction. Leveraging Digitalization in Wire Harness Manufacturing. Lapp Tannehill offers the Wire Harness Manufacturing industry decades of experience in cabling and wire harness solutions, having served over 450 wire harness manufacturers. What is a Wire Harness Manufacturer? Be sure, then, to use those recommendations—such as stripped and bare or stripped and tinned—as that is what the component is built for. A Wire Harness Manufacturer is a company or business that provides services to complete the wire harness assembly process. You should know more to make the right choice. Wire harnesses offer a range of benefits, such as: Wire harnesses are used in far too many applications to list here, but here are some specific examples of notable use cases for wire harnesses: These examples only make up a tiny fraction of relevant use cases for wire harnesses, which see extremely broad usage across major industries such as appliances, construction, heavy and industrial equipment, electronics, military and defense, medical equipment, and many others. Our cutting equipment can cut with speed and accuracy. Coaching children’s recreational league basketball when my kids were growing up was very rewarding—even if it was more like herding cats than playing actual basketball. The process starts with design and development of the wire harness. Variosystems wire harness production video Sri Lanka. Our process begins with a customer who approaches us with a question and design requirements. Wire harnesses are bundles of electrical wires that each have their own individual covering but are also bound together using an additional outer covering. Optimizing space by grouping wires together, Facilitating customization for specific application needs, Providing extended service life on cables and wires, Availability in a broad range of sizes and lengths, Applying fabric tape in varying locations and amounts, Crimping terminals onto wires, which sometimes requires multiple crimping operations, Fastening strands of clamps, cable ties, or tape, Ultrasonic welding for in-line wire splicing. New Solutions Automate Wire Harness Production Line Balancing Since its invention in the late eighteen hundreds, the automobile has become an integral feature of modern society and culture. Some wires will remain outside of connectors and attached to the original equipment individually. We manufacture to the IPC/WHMA-A-620 quality standard.. If you take your time, you will find the process to be less demanding. Need a hand with a current or future PCBA project? Building on 30 years of experience, enterprise-wide software, and management commitment—we have the answers to your PCB challenges. In a nutshell, a wire harness assembly is the binding process of wires, terminations, and connectors within insulated materials. Including quality assurance, signal integrity analysis, environmental analysis, and custom designs. In fact, we excel at manufacturing the largest, most complex wire harnesses in the most cost-effective way possible. We can provide a solution. Wire harnesses typically provide a bunch of cables and wires with some degree of protection and keep them organized, while cable assemblies bind multiple covered wires tightly with a covering to provide robust protection suitable for more demanding environments. Discussing the Advantages of Multilayer PCB, How to Prevent Solder Bridging During PCB Assembly, How to Maintain Quality Control in Electronics Manufacturing, PCB Defect Detection Strategies for Bare vs. Wise Harness Solutions utilizes a complete process controlled manufacturing system. Today, approximately 85% of all wire harness manufacturing operations are carried out manually. This ensures that only the highest quality harnesses leave our facility https://blog.jemelectronics.com/wire-harness-manufacturing-process Specific UL-coded wire may not be essential for the harness and instead could turn out to be difficult to find or expensive to use. ©2017 Precision Manufacturing Company Inc. All rights reserved. 6190 San Ignacio Ave. Some types of terminals include ring, tongue, spade, flag, hook, blade, quick-connect, offset and flagged. This gives the CM the flexibility to use what works best for the harness requirements that is also readily available and cost the least. The first step in the manufacturing process is to discover the problem that the wire harness or cable assembly is meant to solve. The vehicle manufacturer provides the harness manufacturer with a 150-percent-drawing of the design of the on-board wiring system. Key Points of the Manufacturing Process to Build Your Wire Harness. However, as with anything that is manufactured, the more. Assembled Boards, Rapid PCB Prototyping: Breaking Down the Requirements, PCB Material Properties That Can Impact Board Manufacturability, Six Challenges of Medical Device Product Development, PCB Heat Dissipation Techniques to Protect Your Board. First off, your CM will examine your bill of materials and other documentation to make sure that everything they need is in place. Our wire harness assembly services include: Please contact us or request a quote for more information about our wire harness options and capabilities. If needed, the wires will then be inserted into a connector housing, allowing the mating of male and female bundles of wires. A wire harness must also be manufactured with a terminal, defined as "a device designed to terminate a conductor that is to be affixed to a post, stud, chassis, another tongue, etc., to establish an electrical connection." Here are more details of the wire harness manufacturing process that your contract manufacturer should go through when building your assemblies. Standardization provides known cycles and takt times, simplifies training, provides a flexible and multiskilled workforce, creates a visual factory, identifies waste, provides a measurable quality control system, and provides a performance measure for employee reviews and improvements. You have a need. Additionally, the assembly panel will be created with all the necessary pegs set at the specified locations. Part 2 will continue this discussion and demonstrate the benefits of digitalization and MBSE for wire harness manufacturers. Now, the harness will be built. Next, the ends of the wires are stripped to expose the uninsulated conductor and fitted with any required terminals or connector housings. Wire harness manufacturing continues to be an extremely labor-intensive process. by Donnie Hill | Apr 15, 2020 | Wire Harnesses | 0 comments. that has been prepared for it to check continuity. Harness Manufacturing Software. The Dos and Don’ts of Having Your Wire Harness Built, , we have been building wire harnesses for our customers for a long time. New applications for wire harnesses Aluminum Wires in Automobile Harnesses The Ultrasonic Metal Welding process has never been as popular as it is today, yet equipment manufacturers have never been challenged as they have in the last couple of years. Your email address will not be published. Wire harness assemblies are often confused with cable harness assembly. ... Wire Harness Manufacturing - A Division of JC Manufacturing … A … Early vehicles, even those with electric propulsion systems, were primarily achievements in mechanical design and engineering. After all, the full automation of these processes, complete with integrated quality monitoring, is the only way to assure maximum quality and efficiency. Cable Assemblies Manufacturing Process. The final step in the harness manufacturing process is extensive quality control testing. To distinguish between the two, a cable assembly is an external connection to devices and will have different environmental considerations, such as their thickness, insulation type, and flexibility. Car companies have started to take interest in using Wire harnesses are bundled processed wires with a protective covering to guard against wear and tear due to environmental conditions and other potential damaging factors. (847) 615-7100 Facebook However, the vehicle manufacturer regularly issues … The term wire harness is sometimes used interchangeably with cable harness or cable assembly, though there are subtle differences between them. The next step usually involves wire cutting, stripping, and terminating. Once a design is established, the process of building a wire harness starts with the development of a schematic that is used to create the manufacturing paperwork and the assembly board for the harness. Despite the product names, both cables and wires may be found within wire harnesses and cable assemblies. Here is a sampling of the data that will best help your contract manufacturer when building your wire harness: Detailed connectors images that show pin locations. They may have a protective sheath around the wires that is typically made of thermoset or thermoplastic material, which provides additional protection against damage to the individual wires. When it finally came together in a game, it was a beautiful thing to see. A wire harness, on the other hand, will provide the connectivity between systems in an electromechanical assembly, such as connecting a power supply to a motherboard. There’s a lot more to the process of course, and thankfully, the wire harnesses usually don’t talk back to us. We also have a staff of engineers who can answer your questions on wire harnesses and offer recommendations on how best to design them. Crimping wires as part of the wire harness manufacturing process may seem like a no-brainer step where any crimp will do. The component manufacturer usually provides termination recommendations for how the wires should be attached. The manufacturing process for wire harnesses can go from basic to very complex. Wise Harness solutions is a manufacturer of high-quality wire harnesses, control panels, and battery cables for a variety of applications. 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